US 12,188,376 B2
Composite guide vane with insert
Barry Barnett, Unionville (CA)
Assigned to PRATT & WHITNEY CANADA CORP., Longueuil (CA)
Filed by PRATT & WHITNEY CANADA CORP., Longueuil (CA)
Filed on Mar. 29, 2023, as Appl. No. 18/128,112.
Prior Publication US 2024/0328322 A1, Oct. 3, 2024
Int. Cl. F01D 9/02 (2006.01); B32B 3/26 (2006.01); B32B 5/02 (2006.01); B32B 5/26 (2006.01); B32B 38/18 (2006.01)
CPC F01D 9/02 (2013.01) [B32B 3/263 (2013.01); B32B 5/02 (2013.01); B32B 5/26 (2013.01); B32B 38/1808 (2013.01); B32B 2260/023 (2013.01); B32B 2260/046 (2013.01); B32B 2305/076 (2013.01); B32B 2603/00 (2013.01); F05D 2220/32 (2013.01); F05D 2230/23 (2013.01); F05D 2240/12 (2013.01); F05D 2300/603 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A composite guide vane for a gas turbine engine, the composite guide vane comprising:
a body having a longitudinal axis, the body including:
a composite laminate made of an assembly of layers of a first fibrous composite material, the composite laminate defining a mid portion of the body for interacting with a fluid and an end portion of the body disposed axially of the mid portion of the body; and
a composite insert disposed inside the composite laminate and made of a second fibrous composite material, the composite insert extending axially from the end portion of the body into the mid portion of the body and terminating in the mid portion of the body; and
a head or foot overmolded onto the end portion of the body so that the head or foot is fused with the composite laminate,
wherein:
the composite laminate includes a first matrix material;
the composite insert includes a second matrix material fused with the first matrix material of the composite laminate; and
the head or foot is made of a third fibrous composite material including a third matrix material directly fused with the first matrix material of the composite laminate and with the second matrix material of the composite insert.
 
15. A method of manufacturing a composite guide vane of a gas turbine engine, the method comprising:
receiving a layup including fiber-reinforced composite sheets and a composite insert disposed between the fiber-reinforced composite sheets;
consolidating the layup into a unified body using heat and pressure, the body having a longitudinal axis and including a mid portion for interacting with a fluid and an end portion disposed axially of the mid portion, the composite insert extending axially from a first location in the end portion to a second location in the mid portion; and
injection overmolding a head or foot of the composite guide vane onto the end portion of the body so that the head or foot is fused with the end portion of the body.